Systems We have the solution. You have all the options.

Transcription

1 Systems We have the solution. You have all the options.

2 02 Automation from DMG MORI Efficiently improve productivity and process reliability. Automated processes now offer the highest productivity increase potential. At the same time, consistent production quality is achieved. This leads to economic success, while the growing pressure of rising costs is countered efficiently. Many companies see additional value in automated processes. Highly qualified employees are free to carry out other work thanks to automated processes, which means greater availability of skilled staff and savings for the company. DMG MORI Systems supports you with many years of experience and a broad knowledge base in all fields of automation. Potential for raising performance + + Increased competitiveness and profit / returns + + Increased productive time (e. g. operation during staff breaks or reducing non-productive time) + + Reduced labour costs and staff requirements + + Advantages of mass production, even for small batch sizes Jürgen Groß Managing Director Contact: DMG MORI Systems GmbH Antoniusstraße 14, Wernau Tel.: +49 (0) 7153 / info@dmgmori.com + + Manual operation is still possible + + Optimal utilisation of production capacities + + Consistent high quality + + Standardisation of operations + + Efficient space utilisation + + Increased flexibility

3 Assembly hall of DMG MORI Systems in Hüfingen category 1 dmg mori systems DMG MORI Systems Experience and expertise more than 3,000 successful projects. Multiply your performance with automation solutions from DMG MORI Systems. We guarantee perfect work flows and maximum efficiency for your production. DMG MORI offers you the know-how and the technology for the lowest workpiece costs with the highest quality. Our experience spans simple machine integrated automation to planning and implementation of complex manufacturing cells or production lines. category 2 category 3 category 4

4 04 DMG MORI Systems Our 360 solution skills analysis, consultation, implementation. 1 DMG MORI Systems opens all the doors for you to achieve top performance. For this purpose we combine our core business, machine tools, with cutting edge engineering and expertise in automation. Our customers benefit from precisely tailored solutions. Whether you just want to automate one machine or an entire production line or manufacturing cell with multiple machining steps, DMG MORI Systems will develop and implement the perfect solution for you. 2 Production planning + + Process analysis + + Technology planning + + Machine design + + Cycle calculation + + Simulation Production logistics + + Automation planning + + Material flow analysis + + Layout planning Start-up support + + Training + + Process visualisation + + Back up strategy + + Remote diagnostics 1: Planning, engineering 2: Simulation 3: Implementation 3

5 05 DMG MORI Systems expertise in four categories category 1 dmg mori systems category 1 // pages Machine integrated automation category 2 // pages Standard automation category 3 // pages Flexible manufacturing cells category 4 // pages Production lines Overall solutions in category 2 Rotary and linear storage Workpiece or pallet handling Linking of multiple process sequences series production As an optional accessory for the machine, DMG MORI factories offer a range of automation solutions that can be integrated into the machine. Efficient robot and portal solutions with additional modules (cleaning, measuring, deburring, etc.); available as plug and play solutions or in custom configurations. Portal solutions, fixed or mobile robots and extra modules for loading multiple machines for integrated additional operations. Planning and implementation of pallet, portal and robot handling in a production line. category 3 Possible number of automated machines: 1 Possible number of automated machines: 1 2 Possible number of automated machines: 3 5 Possible number of automated machines: > 5 category 4

6 06 Category 1: Machine integrated automation Category 1 Machine integrated automation Packaged solutions from the DMG MORI factories. DMC 60 H linear with RS 12 NMV3000 with AWC 34

7 07 Customer: Erhart GmbH Category 1 Machine integrated automation DMC 65 monoblock with RS 3. Workpiece: Individual and series parts in the field of mechanical engineering + + DMC 65 monoblock with RS Production of series and individual parts + + Production of components for tool magazines + + Machining of aluminium and steel components with a 200 Nm motor spindle + + High degree of machine capacity utilisation thanks to pre-setting on a total of 3 pallets + + Reduced non-productive time thanks to offline set up during machining + + High flexibility category 4 category 3 category 2 category 1

8 08 Customer: KBA-Mödling AG Category 1 Machine integrated automation DMC 210 U with RS 3. Workpiece: Multiple individual parts in plant construction + + DMC 210 U with RS Diverse, highly varied components + + Set up of individual parts during machining + + Use of sister tools due to high strength steels axis simultaneous machining of complex components + + Universal machine for complex machine components + + Rotary pallet storage for portal machines

9 09 Customer: Mechanical engineering supplier Category 1 Machine integrated automation DMC 160 U duoblock with RS 4. Workpiece: Diverse individual parts for mechanical engineering + + DMC 160 U duoblock with RS Use of the machine as a universal milling machine + + High variation of mechanical engineering components + + The challenge: minimise setting times for individual parts + + Process monitoring by means of MPC (Machine Protection Control) + + Maximum machining precision, even with large components + + Maximum flexibility thanks to 5-axis machining of large components measuring up to ø 1,500 mm and weighing up to 4,000 kg + + Unmanned shifts when machining multiple component types thanks to the rotary storage with 6 pallets in the system + + Reduced non-productive time thanks to set up during machining + + Good experience with existing identical machines category 4 category 3 category 2 category 1

10 10 Customer: Caterpillar Energy Solutions GmbH reduced nonproductive time thanks to set up during machining Category 1 Machine integrated automation DMC 80 U duoblock with RS 5. Workpiece: Gas engine connecting rods DMC 80 U duoblock with RS Turnkey project including tools, fixtures and program + + Two identical sister machines + + Four clamping operations on hydraulic fixtures + + Gear grinding on an external grinding machine + + Connecting rod eye measurement with BLUM bore gauge + + Key feature measurement with a measuring sensor + + Readjustment of tool offsets on the basis of the gauge measurement and automatic remachining + + Process reliability through collection and analysis of measurement data + + Large product range to choose from + + Extensive experience in turnkey projects

11 11 Customer: Clamping and gripping technology Category 1 Machine integrated automation DMC 60 H linear with RS 12. Workpiece: Production of individual clamping elements + + DMC 60 H linear with RS Production of individual parts + + Process monitoring with MPC (Machine Protection Control) + + Maximum productivity with 12 pallets in the system + + Linear drives on the X, Y and Z axes with a 60-month warranty + + High dynamics with 100 m/min rapid traverse and 1 g acceleration + + Intelligent tool magazine with 303 tools for set up during the cutting cycle + + Chip to chip time of 2.5 seconds + + Maximum productivity and flexibility category 4 category 3 category 2 category 1

12 12 Customer: Welser Profile Deutschland GmbH minimal footprint of just 26.8 m 2 Category 1 Machine integrated automation DMC 65 monoblock with RS 20. Workpiece: Various small batch components, primarily special punching and cutting tools + + DMC 65 monoblock with RS Machining / post processing of special tools + + Few or no operators during weekend shifts when machining multiple different parts + + Reduced set-up times thanks to fixtures on the machine pallet + + Minimal errors thanks to program assignment to the pallet + + Reduced non-productive time, especially with short machining cycles, thanks to rotary storage with 20 pallets in the system + + The high number of pallets allows the operation of multiple machines + + High number of pallets in a small footprint of just 26.8 m Rapid tool change system with 120 magazine pockets

13 13 Customer: Aerospace sector Category 1 Machine integrated automation CTX beta 800 4A with integrated workpiece handling. Workpiece: Chuck components up to ø mm and 15 kg CTX beta 800 4A with integrated workpiece handling and pallet conveyor + + NC-controlled loading and unloading with double gripper + + Programming of automation using the machine control system + + Manual pallet loading + + Workpiece feed by pallet conveyor and double gripper + + Workpiece machining on the CTX beta 800 4A + + Reduced non-productive time thanks to unloading during machining % shorter loading time than with external loading portals + + Space saving design + + Full integration into the machine control system + + A complete solution from one supplier also means only one contact partner category 4 category 3 category 2 category 1

14 14 Category 2: Standard automation Examples of additional operations 1: Deburring 2: Engraving with needle embosser 3: Combined grinding and brushing station 4: Measuring with touch probe 1 Category 2 Standard automation improve added value and productivity with additional operations. All automation solutions from DMG MORI Systems with 6-axis industrial robots or a portal loader can be equipped with additional operations which the automation system carries out during machining. By reducing manual intervention and improving value creation at the same time, cost effectiveness in production can be significantly increased. 2 Old value added chain Turning / milling Deburring Labelling 3 2 shifts New value added chain with automation from DMG MORI Systems Turning / milling, deburring, labelling 1 shift time saving 1 shift 4

15 15 Customer: Electronics sector Category 2 Standard automation WH 3 as an assembly cell. Workpiece: Sensor housing in varying sizes + + Workpiece handling up to 3 kg, assembly cell for sensor housing + + Full production process with hydraulic press + + Component handling by a 6-axis industrial robot + + Hydraulic press with quality control + + Components are fed in via vibrating helical conveyors + + Workpiece discharge through a paternoster system + + Simulation and system operation on a 21" monitor + + Process monitoring by SPC is possible + + Rapid set-up for a new batch + + Process reliability thanks to in process measurements + + Fewer operator hours required + + A contact partner for service queries + + Proximity to the factory category 4 category 3 category 2

16 16 Customer: EMOD MOTOREN GmbH high flexibility and low space requirements Category 2 Standard automation WH 10 top on CTX beta 800. Workpiece: Shafts for electric motors + + WH 10 top on CTX beta Workpiece feed and removal with the rotary magazine + + Maximum handling weight of over 20 kg, YASKAWA MOTOMAN robot + + External turning on the CTX beta Quick gripper jaw change system for various workpiece geometries + + The gripper jaws are safely indexed with binary coding + + Temporary workpiece storage on the machine roof for quick loading and unloading + + Machining of 20 different shaft types ranging from ø 16 mm to ø 65 mm, lengths from 100 mm to 800 mm + + High flexibility thanks to interchangeable workholding devices and gripper jaws + + Low space requirements + + Fewer operator hours required + + A complete turnkey solution from a single source

17 17 Customer: Manufacturer of communication technology Category 2 Standard automation Portal system with NLX2500/700. Workpiece: Cylinder (ø 40 mm L 390 mm, 3 kg) + + NLX2500/ Portal (LG05) + + Stacking carousel + + Automatic workpiece delivery with the stacking carousel + + Loading and unloading via the portal system + + Maximum workpiece quantity: Stacking cell with space for up to 28 containers category 4 category 3 category 2

18 18 Customer: Mladen Kovacevic CNC-Drehteile over 80 systems of wh 3 installed! Category 2 Standard automation WH 3 on MILLTAP 700. Workpiece: Various ranges MILLTAP 700 with WH 3, workpiece handling up to 3 kg + + Compact automation solution for short machining times + + Tool changing with a 6-axis industrial robot + + Loading by MOTOMAN robot + + Workpiece machining on the MILLTAP Workpiece storage in a paternoster system + + Highly automated thanks to the high workpiece storage capacity + + Double gripper system for rapid workpiece changing + + The workpiece can be changed quickly + + High degree of automation with no intervention by the operator + + Additional stations can be added at a later date + + Fewer operator hours required + + A complete solution from one supplier + + Low space requirements + + Quick start up

19 19 Customer: Speth Zerspanungstechnik GmbH & Co. KG Category 2 Standard automation WH 10 on DMU 70. Workpiece: Various + + DMU 70, WH 10 standard, workpiece handling up to 10 kg + + Continuous workpiece loading and unloading + + Fixture handling with a 6-axis industrial robot + + Feeding of components with the MOTOMAN robot + + Workpiece machining on the DMU High level job management + + Workpiece storage in 4 drawers, each with 2 pallets + + Double gripper system for changing components within the machine + + Turning station integrated into the cell for complete machining + + SPC and measuring capability + + A complete solution from a single source + + Standard machine components flexibly adapted for customer value + + Rapid delivery time category 4 category 3 category 2

20 20 Customer: EKU FREN KAMPANA VE DOKUM SAN. A.S, Turkey Category 2 Standard automation VL-553MCII & VL-553II workpiece handling. Workpiece: Brake disc + + VL-553MCII + + VL-553II + + Robot + + Conveyor for loading and unloading + + Multi stage milling station + + Turning station + + Blow-off station + + Automatic workpiece transportation on the conveyor + + Automatic loading and unloading by robot + + Multi stage milling with vision system + + Turning station + + Blow-off station + + Precise multi stage milling with the vision system and robot + + Set up of the entire system (turning machine and automation)

21 21 Customer: Atlantic Zeiser over 90 units of ph already sold! Category 2 Standard automation PH on DMU 40 evo. Workpiece: Pallets with various workpieces DMU 40 evo with PH 150 8, pallet handling with 24 pallets + + Pallet change via rotating table + + Linear feed + + Workpiece machining on the DMU 40 evo + + Number of available pallet slots: Can machine workpieces measuring up to 150 mm in diameter + + Integrated job management system for individually prioritising jobs + + Batch sizes of 1 can be produced + + High degree of automation with no intervention by the operator + + The priority list can be flexibly changed during production + + Highly flexible pallet handling for processing jobs with a minimum batch size of A complete solution from one supplier also means only one contact partner + + Price, customer satisfaction and compatibility + + Compatibility with existing DMG MORI products category 4 category 3 category 2

22 22 Customer: Car supplier Category 2 Standard automation NT4250 with portal loader. Workpiece: Automotive workpieces + + NT4250DCG/1500SZ + + Portal + + Workpiece buffer + + Automatic loading and unloading portal + + Workpiece transfer between spindles 1 and Gantry robot with a high load capacity (up to 20 kg) + + Full machining on one machine thanks to transfer of the workpiece between the spindles + + Saves time thanks to complete machining and automatic loading and unloading + + Customised turnkey solution

23 23 Customer: Fischer GmbH Kunststoff Präzision Category 2 Standard automation Pallet handling on DMU 60 evo. Workpiece: Various DMU 60 evo, pallet handling up to mm, max.100 kg + + Job management system Pallet changing with a 6-axis industrial robot 2 Workpiece loading by the FANUC robot 3 Workpiece machining on the DMU 60 evo 4 High level job management 5 Simulation and system operation on a 21" monitor 6 Can be expanded with additional machines and pallet storage systems + + Compatible with jobs having a batch size of Higher flexibility thanks to random processing or based on a priority list + + Varied expansion options + + Fewer operator hours required + + Integration of various machining processes + + A complete solution from a single source, flexible system design + + Quick delivery times + + Attractive prices + + Expandability category 4 category 3 category 2

24 24 Customer: Stryker GmbH & Co. KG various expansion options Category 2 Standard automation Combination of workpiece and pallet handling on HSC 55. Workpiece: Variable HSC 55, pallet handling up to mm, max. 30 kg + + Job management system Job related workpiece and equipment management by a high level cell control system 2 Preparation for the integration of a second machine 3 Maximum handling weight of 60 kg thanks to the KUKA KR60 6-axis industrial robot + + Jobs with a batch size of 1 can be processed + + Higher flexibility thanks to random processing or based on a priority list + + Various expansion options + + Fewer operator hours required + + Integration of various machining processes Flexible system design + + Enhanced interface between automation equipment and the machine

25 25 Customer: Tool and mould construction pallet and workpiece handling combined Category 2 Standard automation Pallet handling on DMU 80 P duoblock. Workpiece: Variable DMU 80 P duoblock, combined workpiece and pallet handling up to mm, max.180 kg + + Job management system 1 Pallet changing with a 6-axis industrial robot 2 Workpiece machining on 2 DMU 80 P duoblock High level job management 4 Automatic gripper change from pallet to workpiece handling 5 Pallet storage system + + Jobs with a batch size of 1 can be processed + + High flexibility thanks to random processing or based on the individual machine priority list + + Less operator supervision required + + Unmanned shifts are possible + + A complete solution from a single source, flexible system design + + The ability to handle pallets and workpieces category 4 category 3 category 2

26 26 Customer: Techno-Metal Co., Ltd. low space requirements Category 2 Standard automation Portal system with NZX-S1500/500. Workpiece: Drive shaft NZX-S1500/ Portal loader (LG05) + + Centring station + + Turnover station + + Pallet changer + + Automatic workpiece transportation via the pallet changer + + Automatic loading and unloading with the portal system + + Turnover station + + Centring station + + Saves 153 minutes of the operator s time + + Capacity for 108 workpieces in the buffer store + + Set up of the entire system (turning machine and automation)

27 27 Customer: alutec metal innovations GmbH & Co. KG Category 2 Standard automation Handling for a hydraulic press. Workpiece: Housings + + Handling for a hydraulic press Loading and unloading of the 1,250-tonne press 2 Blanks are fed in on synthetic fibre belts 3 Finished parts (housings) are discharged on a stainless steel chain link belt with separating strips 4 The sensors can detect slugs amongst the various workpieces 5 Press loading and unloading with a FANUC M710iC-70 6-axis industrial robot (overhead suspension) 6 Fully automatic gripper change system for raw and finished parts + + Continuous workpiece processing + + Process reliability thanks to component type and position detection + + The feeding systems can be integrated flexibly due to the design of the safety fence + + Fewer operator hours required + + Creative and innovative solutions + + Years of reliable cooperation + + Simultaneous engineering category 4 category 3 category 2

28 28 Customer: DMG MORI Co. Ltd. Category 2 Standard automation CPP system with NHX10000.

29 29 Workpiece: Machine table, table slots + + NHX Swivelling set up station + + Fixed set up station pallet spaces CPP + + Carrier pallet pool system + + Set up station with ID system + + Set up station with swivel unit + + The set up station with swivel unit facilitates loading and unloading + + A huge variety of workpieces can be managed in the system + + The integrated pallet ID system facilitates the handling of equipment and workpieces (MCC-LPSIII software) category 4 category 3 category 2

30 30 Category 3: Flexible manufacturing cells Category 3 From the blank to the finished piece complete machining according to your requirements. In this category we project manage the entire material flow for your workpiece. Together we will establish the best way to interlink different machine tools. Of course we will incorporate additional, operations such as deburring, cleaning or assembly, into the optimal workflow. As a result you get an automated cell offering maximum productivity. Your benefits + + Tailored to individual requirements _ Requirements analysis _ Value added projection _ Communication with ERP systems _ Modular solution + + Most efficient space utilisation + + Large workpiece weights possible + + Unmanned production + + Just-in-time production + + Turnkey projects + + Medium and large batch sizes _ Optimised machining steps in the machine _ Optimised loading and unloading of the machines _ Automation of subsequent steps + + Large number of workpiece variants _ Automated changing of various workpiece types _ Machining of a mixture of various workpieces

31 31 Customer: Car supplier very short cycle time Category 3 Flexible manufacturing cells fully automatic restacking cell. Workpiece: Gear shaft + + Restacking cell; transfer from transport baskets into temper baskets Restacking of components in a wire basket for annealing 2 2 KUKA robots 3 Transfer station 4 Stack transportation 5 Central computer software with re-tooling strategy 6 2 portal Reduces labour + + Space saving concept + + Avoidance of errors + + Visualisation of the robot and portal in one control system + + Cycle time: 6 seconds per workpiece + + Expertise in robot and portal technology + + Very short cycle time category 4 category 3

32 32 Customer: Schmiedetechnik Plettenberg GmbH & Co. KG 35% higher productivity Category 3 Flexible manufacturing cells Full machining of gear shafts. Workpiece: Gear shaft NZX2500 (OP10), 2 CTV 250 (OP30), 1 Profiroll (OP20) + + Linked complete machining + + Integration of a range of additional operations Workpiece feed and discharge on conveyor belts 2 Feeding with a FANUC robot 3 External turning on the NZX Gear cutting on the Profiroll 5 Internal turning, CTV Cleaning station 7 Marking station 8 Optional measuring equipment Seamless component tracking + + High flexibility thanks to 2 parallel production lines + + Low space requirements + + Less labour required + + A complete turnkey solution from a single source + + Continuous workpiece tracking

33 33 Customer: Karl Völlm GmbH & Co. KG spacesaving solution Category 3 Flexible manufacturing cells Production of bearing housings. Workpiece: Bearing housing for commercial vehicles DMC 60 H linear + + Robot loading The operator loads the components into loading drawers for the robot 2 The robot loads the machine with 4 blank parts 3 After the machining process, the robot removes the individual components whilst simultaneously loading the next blanks 4 The machined components are deburred in a deburring station in the robot cell while the next parts are being machined Partial automation for approx. 30 minutes; components cannot be placed wrongly as special position matrices are in use + + The operator can monitor several machines at once + + Thanks to the large Y axis of the DMC 60 H linear, four components can be mounted on one set up tower only three could be mounted in the past + + Highly compact set up area + + Integrated component deburring category 4 category 3

34 34 Customer: ZF Saarbrücken Category 3 Flexible manufacturing cells Loading and unloading of measuring machines. Workpiece: Centre gear + + Linkage of 4 measuring machines + + Re-stacking cell; transfer from transport baskets into annealing baskets Workpiece supply in stack of annealing trays 2 Transfer unit (portal) between stations 3 Integrated measuring station 4 Conveyor feed for individual parts 5 Workpiece discharge in a stack of wire baskets Avoidance of errors + + Pays for itself in under one year + + Process optimisation with the customer + + Fewer operator hours required + + Cycle time: 12 seconds per workpiece Experience with complex systems + + Good project management

35 35 Customer: Automotive industry seamless component tracking Category 3 Flexible manufacturing cells Linked to a grinding machine. Workpiece: Camshaft + + Linking of 6 grinding machines + + Stacking cell; workpieces in wire baskets, transportation via the portal Workpiece feed and discharge with the pallet storage 2 Portal unit with H loader 3 NZX2000SY grinding machines 4 Orientation station with DMC reader 5 TRT dry cleaning 6 Shaft holding function on the gripper Connection to central computer + + High flexibility thanks to 2 parallel production lines + + Low space requirements + + Fewer operator hours required + + A complete turnkey solution from a single source with third party machines + + Quick delivery times category 4 category 3

36 36 Customer: Car supplier intuitive factory planning by dmg mori systems Category 3 Flexible manufacturing cells Automation of TEM systems. Workpiece: Ring gear + + Linking of 4 Bosch, 1 Kennametal, 1 Klingelnberg + + Linked thermal energy machining Workpiece feeding and discharge on a pallet conveyor 2 Workpiece stack at pallet unloading point and restacking 3 Assembly of the hold-down clamp on the TEM (thermal energy machining) fixture 4 Integrated measuring parts drawer 5 Loading of a measuring machine 6 Stacking of trays in wire baskets Seamless component tracking + + High flexibility thanks to 3 parallel production lines + + Fewer operator hours required + + Integration of various machining processes Complete factory planning by DMG MORI Systems + + Project management by DMG MORI Systems

37 37 Customer: KOEPFER Zahnrad- und Getriebetechnik GmbH over 60 systems successfully installed Category 3 Flexible manufacturing cells Workpiece handling for generative grinding machines. Workpiece: Various + + Workpiece handling on Reishauer RZ150, RZ160, EMAG VL5, EMAG VSC250 1 Loading machines with workpieces 2 Integration of subsequent processes, e. g. cleaning, measuring, testing, aligning, deburring Tried and tested automation solution + + Minimal space requirements A complete solution from a single source + + Flexible system design + + Cooperation backed up by over 60 systems so far + + Quick delivery times category 4 category 3

38 38 Customer: Aviation sector minimal labour for production Category 3 Flexible manufacturing cells Production of turned parts. Workpiece: Screw / pan head screw + + Linking of 1 CTX alpha 300 and 1 CTX alpha Linked complete machining + + Integration of various machining processes + + Workpiece feed and discharge with a stacking carousel portals with l loader + + Turning on the CTX alpha 300 / Blow-off station + + Engraving including test function + + Measuring device drawer + + Low space requirements / minimal operator attendance + + Clear processes + + Less operator supervision required + + A complete turnkey solution from a single source + + Development of a rolling and pressing unit

39 39 Customer: Pump manufacturer integration of all processes Category 3 Flexible manufacturing cells Portal system with NLX2500/700 & NLX2500MC/700. Workpiece: Tube + + NLX2500/ NLX2500MC/ GX05 portals + loading of blanks with an automatic centring unit + turnover station + automatic measuring unit + temporary storage + cleaning station + bush feed + finished parts storage + + Loading of blanks including automatic centring unit + + OP1: Loading and unloading the NLX2500/700 with the GX05 portal system + + Work storage (storage of blanks) + + Automatic loading of the machine by the portal + + Turnover unit integrated in the measuring station + + Temporary storage integrated in a transfer unit + + Cleaning station + + Integration of all processes, from the blank to the finished part + + Integration of the automatic measuring unit for quality control category 4 category 3

40 40 Customer: Car supplier Category 3 Flexible manufacturing cells Independent manufacturing cells. Workpiece: Various sizes CTV 160, 1 DMU 50 ecoline, workpiece handling up to 3 kg + + Full production process in various manufacturing cells + + Tool changing with a 6-axis industrial robot + + Feeding with the MOTOMAN robot + + Workpiece machining on 2 CTV 160 and a DMU 50 ecoline + + Additional operations: Integrated cleaning / weight analysis / measurement / marking + + Custom workpiece feeding via a drawer system, conveyor and paternoster system + + Various batch sizes made possible + + High flexibility thanks to independent manufacturing cells + + Each can be expanded with additional manufacturing cells + + A skilled contact partner for service queries and process analyses

41 41 Customer: Willi Elbe Gelenkwellen GmbH & Co. KG Category 3 Flexible manufacturing cells Workpiece handling for maximum machine capacity utilisation. Workpiece: Parallel machining of three predefined workpieces DMC 55 H duoblock, workpiece handling up to 40 kg 1 Workpiece handling with a 6-axis industrial robot 2 Feeding with the FANUC robot 3 Workpiece machining on 6 DMC 55 H duoblock 6 4 Connection of an additional conveyor to a cleaning machine 5 Load and unload via a custom conveyor belt 6 The system is designed to be modular; it can be flexibly expanded 7 Another system has since been delivered, and it now runs with 2 3 machines High batch sizes made possible + + High degree of machine capacity utilisation through machine prioritisation + + Various expansion options + + Frees up operators from three machines + + Prioritised processing by the next available machine + + Simultaneous machining of 3 different components + + Custom concept development + + A complete solution from a single source category 4 category 3

42 42 Customer: Pump manufacturer Category 3 Flexible manufacturing cells Linking of turning and milling. Workpiece: Bearing flange + + Linkage of DMC 635 V + CTV Workpiece feeding from a rotary parts stacker + + Place the part in the CTV Component at the orientation station + + Place the part in the DMC 635 V + + Storage of finished parts in the pallet cage + + Can be quickly changed + + Independent cell control + + Everything from one source from DMG MORI Systems

43 43 Customer: Home automation and industrial engineering sector Category 3 Flexible manufacturing cells Linkage of a pallet handling portal and robot cell. Workpiece: Stamped parts + + Linking of 2 HSC 20 with PH portal + robot cell + + Pallet handling by robot (pallets measuring ø 100 mm) + + Combined: SAUER portal with 6-axis robot + + Pallets in the cleaning and drying station + + Pallets on the ZEISS 3D measuring machine + + Component engraving by laser + + Transfer to PH in storage + + Independent cell control + + Integrated 3D measuring system + + Best price to performance ratio category 4 category 3

44 44 Category 4: Production lines 1: Cylinder head 2: Universal joint assembly 1 Category 4 The future today material flow in fully automatic production. 2 Your benefits + + System solution for series production (3 10 or more machines) _ Optimised process steps in the machine _ Optimised loading and unloading of machines _ Automation of subsequent machining steps (e. g. cleaning) Large production systems, complex process chains or excep - tionally specialised production: DMG MORI Systems offers you highly efficient solutions for every application designed to maximise output. Make use of our competence in the fields of engineering and technology for fully automated production with the highest degree of economic efficiency. Welcome to the future at DMG MORI Systems. + + Integration of multiple machining centres + + Fully automatic set up points (robots or portal loading) + + Automated functions: Loading and unloading, transport, measuring / testing

45 45 Customer: TSUZUKI MANUFACTURING CO., LTD. Category 4 Production lines Conveyor system with NHX5000 & NVX7000. Workpiece: Gearbox + + NHX NVX fixture store + conveyor + fixture conveyor + fixture lift + fixture transfer unit + + Fixture store (for various workpieces) + + Automatic transfer unit + + Manual conveyor + + Automatic fixture conveyor + + Automatic loading and unloading with an auto coupler + + Simple workpiece changeover + + The manual conveyor facilitates the transportation of heavy workpieces + + The machining process can be visually monitored in case a workpiece needs to be machined differently category 4

46 46 Customer: DMG MORI Manufacturing USA, Inc. unmanned 24-hour operation made possible Category 4 Production lines LPP system with NHX10000 & NH6300 DCGII. Workpiece: Machine table, table slots + + NHX cleaning station + 6-axis robot + set up station + 60 pallet storage spaces + + NH6300 DCGII + cleaning station + 6-axis robot + set up station + 40 pallet storage spaces + + Linear pallet pool system + + Automatic loading and unloading by robot + + Automatic selection of raw material and finished parts by the vision system + + Set up station (frees up operators) + + Automatic cleaning station with a robot + + High storage capacity for different workpieces + + Raw material can be stored in no particular order and processed by priority + + The robot detects the workpiece and acts accordingly, resulting in complete automation + + Full process automation from a single source

47 47 Customer: Great Wall Motor Co. Ltd. Category 4 Production lines Cylinder block line with 18 linked DMC H duoblock. Workpiece: 4-cylinder block, 1.5 l & 1.4 l, 3-cylinder block, 1.3 l DMC 55 H duoblock DMC 75 H duoblock + + Technology (tools, equipment, process and loading / unloading) + + In process measurement and correction of the cylinder bore + + Adjustment of the cutting edge by the internal coolant supply + + Balluff workpiece identification + + Camshaft boring + + Feed and discharge conveyors + + Workpiece turnover station + + A and B machines per operation + + Semi automatic loading + + A cost-effective semi automatic solution + + Reduced post processing work thanks to in process measurement and corrections + + Quick delivery times + + Overall concept a solution based on the customer s specifications category 4

48 48 Customer: Great Wall Motor Co. Ltd. Category 4 Production lines Cylinder block line with 25 linked DMC monoblock / DMC H duoblock. Workpiece: 2 types of cylinder block, 1 mounted longitudinally, 1 mounted transversely DMC 65 monoblock, 13 DMC 55 H duoblock, 3 DMC 75 H duoblock + + Tools, equipment, process and loading / unloading production lines: Pre-machining of the baseplate, pre-machining of the engine block, fine machining of the engine block and assembled baseplate + + In process measurement and correction of the cylinder bore + + Adjustment of the cutting edge by the internal coolant supply + + Camshaft boring and machining + + Semi automatic loading + + Feed and discharge conveyors + + Workpiece turnover station + + Repeat order fulfilled with identical machines + + Universal product ranges + + Quick delivery times + + Extension project / repeat orders

49 Customer: China FAW Group Corporation Workpiece: 3 different types of gearbox Category 4 Production lines Production line with 15 linked DMC H duoblock DMC 55 H duoblock ++ 2 DMC 65 H duoblock ++ Technology (tools, equipment, tool presetter) System project with stand alone machine Machining of 10 different gearboxes Up to 50,000 gearboxes per year Complete component machining ++ High productivity thanks to duplicate machines ++ Universal machine concept featuring different sizes of machine ++ Experience in turnkey projects ++ Universal machine concepts ++ Pricing strategy for horizontal machining centres category 4 49

50 50 Customer: Zhejiang Geely Holding Group Co., Ltd. Workpiece: 1.8 litre car engine Category 4 Production lines Production line with 18 DMC H duoblock DMC 55 H duoblock ++ 4 DMC 75 H duoblock ++ Tools, tool pre-setting device, loading station, roller conveyors, process, equipment Machining a cylinder block ++ Linkage to external machines ++ Component orientation with the turnover station Flexible manufacturing thanks to hand loading Short set-up times High productivity thanks to linked machines A cost effective automation solution Repeat order fulfilled with identical machines 1: Blank machining / roughing 2: Cleaning 3: Pre-machining 4: Assembly 5: Cylinder head assembly and finish machining 6: Cleaning, honing, assembly Price Quick delivery times Experience in turnkey projects Universal machine concepts

51 51 Customer: SANY Group Co. Ltd. Category 4 Production lines System with 12 linked DMC H duoblock. Workpiece: Valve block DMC 80 H duoblock Fastems FPM-1100 (78 pallet storage positions / 2 levels / 2 loading stations) + + DMG Virtual Machine, tool presetter + + Flexible production of various valve blocks on 2 6 DMC 80 H duoblock + + Large number of pallets in the system + + Manual component set up, placed on the storage shelf + + Machine operation with minimal attendance thanks to two set-up stations and 78 pallet storage positions + + High level of automation and production planning + + High flexibility for future expansion + + Machine precision and stiffness + + DECKEL MAHO Fastems partner concept + + Service in China (DMG MORI and Fastems) category 4

52 52 Customer: SANY Group Co. Ltd. Category 4 Production lines System with 10 linked DMC H duoblock. Workpiece: Valve blocks, CK DMC 65 H duoblock Fastems FPM-750 (72 pallet storage positions / 2 levels / 2 loading stations) + + DMG Virtual Machine, tool presetter different components + + Manual fixture ,000 valve blocks per year + + Flexible production of various valve blocks on 2 5 DMC 65 H duoblock, manual component clamping + + Machine operation with minimal attendance thanks to two set-up stations and 72 pallet storage positions + + High level of automation and production planning + + Automation with Fastems FPM Service in China (DMG MORI and Fastems)

53 53 Customer: Weber Automotive Category 4 Production lines Car cylinder heads. Workpiece: Car cylinder head NHX FANUC Track Motion with 3 robots + + Interface for base plates + + Integrated assembly + + Flexible production of cylinder heads + + Workpiece clamping and transport via base plates + + Automatic loading and unloading + + High chip discharge rate via a powerful central system + + High flexibility for the future and component changes + + High process precision + + Low personnel requirements + + Low maintenance costs + + Maximum availability of delivered systems + + Quick delivery times + + Machine price:performance ratio category 4

54 54 Customer: Weber Automotive Category 4 Production lines Engines for construction machines. Workpiece: Cylinder block & head NH8000 DCG + + FANUC Track Motion with 6 FANUC M900iA robots + + Cleaning machine, assembly, seal testing + + Production of the cylinder head and block in two lines + + Unsupported workpiece transportation + + Integrated processes: Measurement, cleaning, assembly identical standard machines + + Maximum machine availability + + Maximum component precision with numerous control points + + High flexibility for the future and component changes + + Machine precision and stiffness + + Quick delivery times

55 55 Customer: Car supplier Category 4 Production lines NL CL2000 with portal loading. Workpiece: Automotive workpieces NL2000/ CL2000B + + Automatic loading and unloading via a gantry robot + + Interconnection of the entire system + + Buffer capacity for a total of 26 pallets + + Shorter cycle time thanks to several loaders for 7 machines in simultaneous operation + + Set up of the entire system (turning machine and automation) category 4

56 56 Customer: Leonberg Pfronten Stuttgart Bielefeld Klaus Pleszew Geretsried Seebach Davis Hüfingen Nara America Europe Asia DMG MORI Manufacturing and Digital Technology Laboratory (DTL) 3805 Faraday Avenue Davis, California DMG MORI Systems GmbH Antoniusstraße 14 D Wernau DMG MORI Systems GmbH Seemühle 5 D Hüfingen DMG MORI Co., Ltd. 362 Idono-cho, Yamato-Koriyama City, Nara kitakoriyama-cho, Yamato- Koriyama City, Nara MAI.D6042_1013_D6449_1115AD11UK 2 DMG MORI Systems GmbH Antoniusstraße 14, D Wernau Tel.: +49 (0) 7153 / 934-0, Fax: +49 (0) 7153 / info@dmgmori.com, Prices and technical details are subject to change without notice. Goods are subject to prior sale. Listed prices and availability valid for delivery from factory (ex works) without packaging. The machines depicted here may include some options, equipment and control alternatives that are not reflected in the listed price. Our general terms and conditions apply.